KR102536445B1 - Automatic piezoelectric stroke adjustment - Google Patents

Abstract

Correcting the firing profile includes applying a voltage to the piezoelectric actuator 34 to move the valve closing structure 18 between non-impact and impact positions, sensing the position of the valve closing structure, voltage and position Setting a reference point using the data, and using the reference point to adjust the applied voltage. Another method uses a mechanical stopper to calibrate the injection system. The method includes applying a voltage to a piezoelectric actuator to move the valve closing structure between non-impact and collision correcting positions, sensing the position of the valve closing structure, generating voltage and position correction data, and generating such data. establishing a master reference point using the master reference point, and using the master reference point to determine wear of at least one of the piezoelectric actuator and the valve closing structure. Another method of activating the injection system involves a user entering information into a control component. Another method includes using the voltage data and position data related to the piezoelectric actuator for preventative maintenance of one or more components of the injection valve.

Description

Automatic piezoelectric stroke adjustment

CROSS REFERENCES OF RELATED APPLICATIONS

This application claims priority to US Provisional Application Serial No. 62/211,961, filed August 31, 2015, the entire contents of which are incorporated herein by reference.

The present invention relates generally to a non-contact, jetting dispenser for depositing small droplets of viscous fluid onto a substrate, and more particularly to a dispenser of this type actuated by one or more piezoelectric elements.

Non-contact viscous material dispensers are often used to apply trace amounts of viscous material, i.e., viscous materials having a viscosity in excess of 50 centipoise, onto a substrate. As used herein, "non-contact" means when the spraying injector does not contact the substrate during the dispensing process. For example, non-contact spray dispensers are used to apply various viscous materials onto electronic substrates such as printed circuit boards. Viscous materials applied to electronic boards include, for example, general purpose adhesives, solder pastes, solder fluxes, solder masks, thermal grease, lid sealants, oils, encapsulants, potting compounds, epoxies, including but not limited to die attach fluids, silicones, RTVs and cyanoacrylates.

The specific applications for dispensing viscous materials from contactless dispensers onto substrates are numerous. Among others, in semiconductor package assembly, underfill, solder ball reinforcement in ball grid arrays, dam and fill work, chip encapsulation, underfilling chip scale packages Applications exist for cavity fill dispensing, die attach dispensing, lid seal dispensing, non-flow underfilling, flux dispensing, and thermal compound dispensing. For surface mount technology (SMT) printed circuit board (PCB) production, surface mount adhesives, solder pastes, conductive adhesives and solder mask materials can be dispensed from non-contact dispensers as well as selective flux dispensing.

Jet dispensers generally include pneumatic or electric actuators for repeatedly moving a shaft or tappet toward a sheet while jetting droplets of viscous material from an outlet orifice of the dispenser. Electrically actuated spray distributors may in particular use piezoelectric actuators. Precise dispensing of fluid using a valve closure structure in contact with a valve seat uses a prescribed stroke (displacement) and velocity to efficiently discharge a dot of fluid material from the outlet of the nozzle. This requires the shaft to come into contact with the valve seat. The displacement and velocity curves collectively form a motion profile. Stroke, speed and sealing force are best controlled when the point of impact between the valve closing structure and the valve seat is accurately known and measured. There must be sufficient force after impact of the valve seat and the shaft to create a seal to prevent leakage of fluid material. However, applying too much force will cause excessive wear or even damage to the components.

Changes of just a few micrometers affect the performance of the fluid distributor. Typically, this adjustment is performed manually by the user through mechanical means such as adjusting a screw. This manual process requires multiple iterations, but still does not fine-tune the motion profile for the required performance. Therefore, there is a continuing need to determine the position of the valve closing structure relative to the valve seat and adjust the motion profile of the fluid dispenser accordingly to optimize the performance and settings of the fluid dispenser.

For at least these reasons, it would be necessary to provide an injection system and method that addresses these and other problems.

In one embodiment, a method of calibrating the ejection profile of an ejected fluid material for an ejection system is disclosed. The injection system includes a spray distributor and a control component operably coupled to the spray distributor. The injection distributor includes a valve seat, a valve closing structure, and a piezoelectric actuator. The method includes applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-impact position where the valve closing structure does not impact the valve seat and an impacted position where at least a portion of the valve closing structure impacts the valve seat. do. The method also includes generating voltage data according to movement of the valve closing structure. The method also includes sensing a position of the valve closing structure using a sensing device as the valve closing structure moves. The method also includes generating positional data in accordance with movement of the valve closing structure. The method also includes establishing a reference point using the voltage and position data. The method also includes using a reference point to adjust the voltage applied to the piezoelectric actuator.

In another embodiment, a method of calibrating the ejection profile of an ejected fluid material for an ejection system is disclosed. The injection system includes a spray distributor and a control component operably coupled to the spray distributor. The injection distributor includes a piezoelectric actuator, a valve seat, a valve closing structure, and a mechanical stopper positioned a predetermined distance from the valve closing structure in a non-impact corrective position. The method includes applying a voltage to a piezoelectric actuator to move a valve closing structure between a non-impact corrective position in which the valve closing structure does not collide with the mechanical stopper and a impact corrected position in which at least a portion of the valve closing structure collides with the mechanical stopper. include The method also includes generating voltage correction data as the valve closing structure moves. The method also includes sensing a position of the valve closing structure using a sensing device as the valve closing structure moves. The method also includes generating position correction data as the valve closing structure moves. The method also includes establishing a master reference point using the voltage and position calibration data. The method also includes using a master reference point to determine wear of at least one of the piezoelectric actuator, the valve closing structure and the valve seat.

In yet another embodiment, a method of calibrating the ejection profile of an ejected fluid material for an ejection system is disclosed. The injection system includes a spray distributor and a control component operably coupled to the spray distributor. The injection distributor includes a valve seat, a valve closing structure, a piezoelectric actuator, and a mechanical stopper positioned a predetermined distance from the valve closing structure in a non-impact corrective position. The method includes applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-impact position in which the valve closing structure does not impact the valve seat and an impact position in which at least a portion of the valve closing structure impacts the valve seat. . The method also includes generating voltage data according to movement of the valve closing structure. The method also includes sensing a position of the valve closing structure using a sensing device as the valve closing structure moves. The method also includes generating positional data in accordance with movement of the valve closing structure. The method also includes establishing a reference point using the voltage and position data. The method includes applying a voltage to a piezoelectric actuator to move a valve closing structure between a non-impact corrective position in which the valve closing structure does not collide with the mechanical stopper and a impact corrected position in which at least a portion of the valve closing structure collides with the mechanical stopper. Also includes The method also includes generating voltage correction data as the valve closing structure moves. The method also includes sensing a position of the valve closing structure using a sensing device as the valve closing structure moves. The method also includes generating position correction data as the valve closing structure moves. The method also includes establishing a master reference point using the voltage and position calibration data. The method includes comparing the reference point to a master reference point to determine wear of the valve seat.

In another embodiment, a method of activating an injection system by a user is disclosed. The injection system includes a spray distributor and a control component operably coupled to the spray distributor. The injection distributor includes a piezoelectric actuator, a valve seat, a valve closing structure, and a mechanical stopper positioned a predetermined distance from the valve closing structure in a non-impact corrective position. The method includes inputting a fluid type into a control component by a user. The method also includes inputting a jetting frequency into a control component by a user. The method also includes inputting a droplet size into the control component by a user. The method comprises applying a voltage to a piezoelectric actuator to move a valve closing structure between a non-collision correction position in which the valve closing structure does not collide with the mechanical stopper and a collision correction position in which at least a portion of the valve closing structure collides with the mechanical stopper. Also includes determining a master calibration profile. The method also includes applying a master regulation profile to the injection system using the control component. The method includes applying a voltage to a piezoelectric actuator to move a valve closing structure between a non-collision correction position in which the valve closing structure does not collide with the valve seat and a collision correction position in which at least a portion of the valve closing structure collides with the valve seat. Also includes determining a calibrated spray profile. The method also includes applying the calibrated injection profile to the injection system.

In another embodiment, a method of performing maintenance on an injection system is disclosed. The injection system includes a spray distributor and a control component operably coupled to the spray distributor. The injection distributor includes a piezoelectric actuator and a valve closing structure. The method includes applying a voltage to a piezoelectric actuator to move the valve closing structure between a first position and a second position. Voltage data is generated as the valve closing structure moves. The position of the valve closing structure is sensed using a sensing device as the valve closing structure moves. Positional data is generated as the valve closing structure moves. Voltage data and position data are used for preventative maintenance.

In yet another embodiment, a method of calibrating the ejection profile of a ejection fluid material for an ejection system is disclosed. The injection system includes a spray distributor and a control component operably coupled to the spray distributor. The injection distributor includes a valve seat, a valve closing structure, and a piezoelectric actuation mechanism having a piezoelectric actuator. The method includes receiving input from a user of a desired stroke length of the valve closing structure. A voltage is applied to the piezoelectric actuator to move the valve closing structure between a non-impact position in which the valve closing structure does not impinge on the valve seat and an impact position in which at least a portion of the valve closing structure impinges on the valve seat. Voltage data is generated as the valve closing structure moves. The position of the valve closing structure is sensed using a sensing device as the valve closing structure moves. Positional data is generated as the valve closing structure moves. Based at least in part on the voltage data and the position data, a reference point is determined. The method further includes determining, based at least in part on the voltage data and the position data, a top voltage corresponding to a position of the valve closing structure that results in a required stroke length of the valve closing structure. The reference point and peak voltage are used to adjust the voltage applied to the piezoelectric actuator.

A method of calibrating the ejection profile of an ejected fluid material for an ejection system is disclosed. The injection system includes an injection distributor and a control component operably coupled to the injection distributor. The injection distributor includes a piezoelectric actuation mechanism having a piezoelectric actuator, a valve closing structure, and a mechanical stopper positioned a predetermined distance away from the valve closing structure in a non-impact corrective position. The method includes applying a voltage to a piezoelectric actuator to move a valve closing structure between a non-impact corrective position in which the valve closing structure does not collide with the mechanical stopper and a impact corrected position in which at least a portion of the valve closing structure collides with the mechanical stopper. include Voltage calibration data is generated as the valve closing structure moves. The position of the valve closing structure is sensed using a sensing device as the valve closing structure moves. Position correction data is generated as the valve closing structure moves. The method further includes determining, based at least in part on the voltage calibration data and the position calibration data, a reference gain representative of a ratio of displacement of the valve closing structure to a voltage applied to the piezoelectric actuator. Based at least in part on the reference gain, a wear characteristic is determined for at least one of the piezoelectric actuation mechanism and the valve closing structure.

Various additional features and advantages of the present invention will become more apparent to those skilled in the art upon review of the following detailed description of exemplary embodiments taken in conjunction with the accompanying drawings.

1 is a cross-sectional view of an injection system in an open position according to one embodiment of the present invention;
Fig. 2 is an enlarged sectional view similar to Fig. 1, in a closed position;
3 is a chart comparing the original and corrected firing profiles.
4 is a flow diagram of a method for calibrating a spray profile according to one embodiment of the present invention.
5 is a chart of a method of calibrating a spray profile according to an embodiment of the present invention where increased measurement positions indicate that the valve closing structure is opening or moving upwards.
6 is a chart of a method of correcting a spray profile according to another embodiment of the present invention using the spray system of FIG. 1 where increased measurement positions indicate that the valve closing structure is closing or moving downwards.
7 is a perspective view of a reference cartridge according to an embodiment of the present invention.
Figure 8 is a perspective cross-sectional view of the reference cartridge of Figure 7 taken along line 8-8;
Fig. 9 is a cross-sectional view of an injection system incorporating the reference cartridge of Figs. 7 and 8 according to an embodiment of the present invention;
10 is a flow diagram of a method for calibrating an injection system using the reference cartridge of FIGS. 7-9 according to an embodiment of the present invention.
11 is a flow diagram of a method for calibrating a spray profile according to one embodiment of the present invention.
12 is a chart illustrating a spray profile according to an embodiment of the present invention.
FIG. 13 is a chart of a method of correcting a spray profile according to another embodiment of the present invention using the spray system of FIG. 1 where increased measurement positions indicate that the valve closing structure is closing or moving downward.
14 is a flow diagram of a method for calibrating an injection system using the reference cartridge of FIGS. 7-9 in accordance with an embodiment of the present invention.

Referring to FIGS. 1 , 1A and 2 , an injection system 10 according to one embodiment of the present invention generally includes an injection distributor 12 communicatively coupled to a control component 14 . The injection distributor 12 includes a nozzle hub 20 having a piezoelectric actuation mechanism 16 , a valve closing structure 18 , and a valve seat 22 . In particular, valve closing structure 18 includes actuation pin 24 and poppet 26 . The spray distributor 12 receives fluid material under pressure from a suitable fluid source 30 through a fluid supply conduit 32 . Actuation pin 24 is actuated by action of piezoelectric actuation mechanism 16 to move tip 70 of poppet 26 toward valve seat 22 and dispense a quantity of fluid material 38 .

The piezoelectric actuation mechanism 16 includes piezoelectric stacks 91a and 91b (hereinafter collectively referred to as piezoelectric stacks 91 ), a plunger 99 , and an asymmetric bend 94 . The flexure 94 is an integral part of the actuator body 98 within which the piezoelectric actuator mechanism 16 is generally disposed, and includes a coupling element 97 connecting the flexure 94 to the plunger 99. . Spring 102 in piezoelectric actuator 34 applies a spring force to plunger 99 and piezoelectric stack 91 to keep them in compression.

Since the voltage applied to the piezoelectric actuator 34 is proportional to the force generated by the piezoelectric actuator 34, the use of the piezoelectric actuator 34 including the piezoelectric stack 91 prevents the injection distributor 12 from closing the valve. It makes it possible to have very specific position control of the structure 18 . Specifically, when a voltage is applied to the piezoelectric stack 91, the piezoelectric actuator 34 expands or lengthens, and the change in length is proportional to the amount of applied voltage. This proportionality allows the injection system 10 to finely control the motion profile of the fluid material 38 dispensed through the outlet 40 . Pneumatic actuators do not exhibit this proportionality.

The plunger 99 serves as a mechanical interface connecting the piezoelectric stack 91 and the asymmetric bend 94 . When the spring 102 is compressed during assembly, the spring force generated by the spring 102 applies a constant load to the piezoelectric stack 91, preloading the piezoelectric stack 91. An asymmetric bend 94, which may be constructed of a metallic material, has an arm 100 to which the end of the drive pin 24 opposite the downward tip of the drive pin 24 is physically secured. The asymmetric bend 94 functions as a mechanical amplifier that converts the relatively small displacement of the piezoelectric stack 91 into a displacement useful to the drive pin 24 that is significantly greater than the displacement of the piezoelectric stack 91 .

The piezoelectric stack 91 of the piezoelectric actuator 34 is a laminate composed of layers of piezoelectric ceramic alternating with layers of conductors common in the art. The spring force from spring 102 holds the stacked layers of piezoelectric stack 91 in a steady state of compression. The conductors of the piezoelectric stack 91 are associated with the control component 14 to supply a current-limited output signal in a manner well known in the art, such as pulse width modulation, frequency modulation, or a combination thereof. It is electrically coupled with the driving circuit. When power is supplied periodically from the driving circuit, an electric field that changes the dimensions of the piezoelectric ceramic layers in the piezoelectric stack 91 is established.

The dimensional change experienced by the piezoelectric stack 91 mechanically amplified by the asymmetric bend 94 linearly moves the drive pin 24 in a direction parallel to its longitudinal axis. When the piezoelectric ceramic layers of the piezoelectric stack 91 expand, the spring 102 is compressed by the expansion force, and the asymmetric bend 94 pivots around a fixed pivot axis, causing the poppet 26 to causes the movement of the drive pin 24 upward and away from This allows the biasing element 39 to move the poppet 26 away from the valve seat 22 . The drive pin 24 is guided using a drive pin guide 50 . When the actuation force is removed and the piezoelectric ceramic layers of the piezoelectric stack 91 are allowed to contract, the spring 102 expands and the asymmetrical bend 94 pivots to move the drive pin 24 downward and into contact with the poppet 26. As a result, the poppet 26 comes into contact with the valve seat 22 to eject droplets of material. Therefore, in a de-energized state, the piezoelectric actuator 34 holds the valve in the normally closed position. In operation, the asymmetric bend 94 energizes and de-energizes the piezoelectric stack 91 to move the drive pin 24 in contact and non-contact with the poppet 26 to eject the droplets at a rapid rate; It oscillates intermittently in opposite directions around a fixed pivot.

In some embodiments, when the piezoelectric stack 91 expands, the actuating pin 24 moves downward and contacts the poppet to dispense a quantity of material from the outlet 40, generally by the piezoelectric actuator mechanism 16 and the dispenser ( 12) can be configured alternatively. Conversely, when the applied voltage is removed from the piezoelectric stack 91 to allow the piezoelectric stack 91 to contract, the drive pin 24 moves upward and away from the poppet 26 . Therefore, in this embodiment, the voltage applied to the piezoelectric stack 91 of the piezoelectric actuator 34 coincides with the downward movement of the drive pin 24 towards the poppet 26 .

Sensing device 48 is responsible for the movement of valve closing structure 18 as the valve closing structure (including its components, such as actuating pin 24 and/or poppet 26) is moved by piezoelectric actuation mechanism 16. detect the location In some aspects, sensing device 48 may be attached directly or indirectly to valve closing structure 18 . A target (not shown) may be placed on valve closure structure 18 such that sensing device 48 reads the position of the target relative to sensing device 48 . For example, FIG. 1 shows sensing device 48 , which is a linear encoder that reads position and motion using lines (not shown) disposed on drive pin 24 . Therefore, the sensing device 48 enables the position and speed of the valve closing structure 18 to be determined as the valve closing structure 18 moves. In other embodiments, sensing device 48 may additionally or alternatively sense the position and speed of poppet 26 . Additionally, the position and velocity of the valve closing structure 18 may be measured using various other types of position feedback devices, such as eddy current sensors or optical proximity sensors.

2 shows a detailed view of the injection distributor 12 in the closed position. As shown, the fluid cartridge 56 is attached to the dispenser 12 and includes a cartridge body 57 and a portion of the valve closing structure 18, shown particularly as the poppet 26. 1 and 2 show the dispenser 12 having a fluid cartridge 56, the fluid cartridge 56 is not required and may be replaced with any other suitable structure. Additional details may be found in Applicant's co-pending US patent application Ser. No. 14/730,522, filed Jun. 4, 2015, entitled "Ejection Cartridges for Fluid Dispensing and Related Methods," which is incorporated herein by reference. .

FIG. 3 shows a chart of the voltage applied to the piezoelectric actuator 34 (i.e., voltage data 76), plotted over a time period resulting in one divider cycle of the divider. The chart shown in FIG. 3 shows that the voltage applied to the piezoelectric actuator 34 (and consequent expansion) causes the actuating pin 24 to move downward and into contact with the poppet 26. ) is considered as a composition. Conversely, the removal or reduction of the voltage to the piezoelectric actuator 34 in this alternative configuration (and the accompanying contraction) causes the actuating pin 24 to move upward and away from the poppet 26, causing the poppet 26 to It makes it possible to engage with this valve seat (22).

Before describing an exemplary method of adjusting the original firing profile 58 to obtain the corrected firing profile 60, it is helpful to first describe aspects of the original firing profile 58 and the corrected firing profile 60. helpful. As used herein, a “profile” is applied to the piezoelectric actuator 34 over a period of time (e.g., a period of time corresponding to a single full up-down reciprocating motion of the valve closing structure 18). range of voltages that can be repeated several times to complete the distribution. Original spray profile 58 generally refers to an initial operating profile before one or more methods described herein are used to calibrate the spray system 10 and/or determine the degree of wear of the spray system 10. do. The calibrated injection profile 60 is generally determined after one or more of the methods described above have been performed, and is preferably applied to the injection system 10 with respect to an optimal sealing fit of the poppet 26 and valve seat 22. refers to an actuation profile that exhibits an improved actuation of

The original spray profile 58 consists of an open profile 62, an on time 64, and a closed profile 66, and can be created in a variety of different ways. Using, for example, a graphical user interface (not shown) associated with control component 14, a user may use a start voltage 36, end voltage 68, and from start voltage 36 to end voltage 68. Define the open profile 62 by selecting the amount of time to advance, and the transition time. Transition time is the amount of time used at the start and end of the open profile 62. Closed profile 66 can be defined in much the same way. The end voltage 68 of the closed profile 66 is typically equal to the start voltage 36 of the open profile 62 . The user can also provide a sealing offset voltage (Vso) which will be described in more detail below. Once the open profile 62 and closed profile 66 have been created, the open profile 62 and closed profile 66 are stored in the library of original firing profiles 58 . The open profile 62 and closed profile 66 may be saved together in a single file. A user may select an on time 64 after selecting a profile, which as used herein refers to the time from the start of the open profile 62 to the start of the closed profile 66 . Also, the on time 64 is greater than the time 62 associated with the open profile 62 .

Using the original spray profile 58 described above, it is beneficial to provide an illustrative example. With continued reference to FIG. 3 , at rest, a maximum firing profile voltage is applied to the piezoelectric actuator 34 to hold the valve closing structure 18 in the closed position. As shown, the open profile 62 starts at 45 volts when in the closed position. The open profile 62 then drops to 5 volts at 200 microseconds to move the poppet 26 away from the valve seat 22 with a transition time of 75 microseconds at each end. With respect to the closing profile 66, for example, the valve closing structure 18 is disconnected from the valve seat 22 in the open position with 5 volts, then with a transition time of 25 microseconds at each end of the valve seat. Increase to 45 volts in 100 microseconds to move poppet (26) towards (22).

In the original firing profile 58 described above, the relevant voltage measurements are now described with continued reference to FIG. 3 . Various example methods may be used to determine the closing voltage Vc in the calibrated firing profile 60 based on the original firing profile 58 . Closing voltage Vc is the voltage at which the tip 70 of the valve closing structure 18 first impinges on the valve seat 22, preferably with the required force and speed. The sealing offset voltage Vso is an additional voltage applied to the closing voltage Vc to achieve a sealing voltage Vs at which a sufficient force is applied to the tip 70 of the valve closing structure 18 to close without leakage. The seal offset voltage Vso depends at least on the type of fluid material 38 being dispensed and the pressure of the fluid material 38, and is typically in the range of about 5 volts to about 30 volts. As noted above, the seal offset voltage Vso is typically a known constant throughout the methods described herein, and may be initially input into control component 14 by the user. The closing voltage (Vc), sealing offset voltage (Vso), and sealing voltage (Vs) are related using the formula Vs = Vc + Vso. In some embodiments, such as the configuration of divider 12 shown in FIGS. 1 and 1A, where downward movement of drive pin 24 and poppet 26 corresponds to a decrease in voltage applied to piezoelectric actuator 34, It should be noted that the sealing offset voltage Vso may be a negative value.

An exemplary method of determining the closing voltage (Vc) is now considered. In one exemplary embodiment, when sensing device 48 indicates one or more continuously non-changing positions of valve closing structure 18 (eg, actuation pin 24 or poppet 26 ), such position. The voltage measurement corresponding to the first position among them considers the closing voltage Vc. In another exemplary embodiment, as shown in FIG. 5 and described in detail later, the closing voltage Vc is determined by a first trend line in a graph of applied voltage plotted against a corresponding measurement location of the valve closing structure 18. It is determined by checking the intersection of (first trendline) 72 and second trendline 74. Using either exemplary method of determining the closing voltage Vc, the reference point RP can be correspondingly determined. The reference point RP reflects the closing voltage Vc and the position of the valve closing structure 18 (eg poppet 26) corresponding to the closing voltage Vc. In the exemplary method 400 (FIG. 4) described below, the original firing profile 58 is based at least in part on the closing voltage Vc and/or the reference point RP to obtain a calibrated firing profile 60. corrected

FIG. 4 shows an exemplary method 400 for adjusting or correcting the original spray profile 58 of the spray system 10 . At step 402, a voltage is applied to the piezoelectric actuator 34 to move the valve closing structure 18 (eg, poppet 26) between the non-impact position 52 and the impact position 54. As used herein, an impact position 54 refers to a position where at least a portion of the valve closing structure 18 physically impacts the valve seat 22, while a non-impact position 52 refers to a position where the valve closing structure 18 physically impacts. The part of (18) refers to a position where it does not collide with the valve seat (22). It does not matter whether the valve closing structure 18 starts at the non-impact position 52 and moves to the impact position 54 or starts at the impact position 54 and moves to the non-impact position 52 . Both arrangements are suitable.

At step 404 , the sensing device 48 senses the position of the valve closing structure 18 as the valve closing structure 18 moves relative to the sensing device 48 . At step 406, control component 14 determines position data 78 (FIG. 5 or 6) and voltage data 76 (FIG. 5 or 6), respectively. Additionally, velocity data (not shown) may be generated as valve closing structure 18 moves relative to sensing device 48, which may include voltage data 76, position data 78, and velocity data. It enables the reference point (RP) and/or the closing voltage (Vc) to be set.

In step 408 , a reference point RP is determined, such as by control component 14 , based on analysis of voltage data 76 and position data 78 . Reference point RP may be determined using a variety of methods, such as representing voltage data 76 versus position data 78. Position data 78 includes non-collision and impact position data.

At step 410 , control component 14 determines a lockout voltage Vc based, for example, at least in part on reference point RP determined at step 408 . For example, since the reference point RP includes both a position component and a voltage component, the closing voltage Vc can be identified from the voltage component.

In step 411, the sealing voltage Vs is determined based at least in part on the closing voltage Vc. For example, the sealing voltage (Vs) can be determined using the closing voltage (Vc) and the sealing offset voltage (Vso) according to the equation Vs = Vc + Vso. It will be appreciated that in some aspects, the seal offset voltage (Vso) cannot be used to perform the dispensing operation. In this configuration, the sealing voltage Vs equals the closing voltage Vc since the sealing offset voltage Vso is substantially zero.

At step 412 , sealing voltage Vc is used to determine a calibrated firing profile 60 . In particular, the original firing profile 58 is shifted into a corrected firing profile 60 based at least in part on the sealing voltage Vs. For example, original firing profile 58 can be modified firing profile 60 such that corrected firing profile 60 includes a starting voltage 36 and/or ending voltage 68 equal to sealing voltage Vs. is shifted to

5 provides an illustrative example of using the intersection of the first trend line 72 and the second trend line 74 to correct the original injection profile 58 . Application of a voltage to the piezoelectric actuator 34 causes upward movement of the valve closing structure 18 away from the valve seat 22, and removal or reduction in the applied voltage results in the distributor shown in FIGS. 1 and 1A ( It should be noted that the chart shown in FIG. 5 considers the distributor as causing a downward movement of the valve closing structure 18 towards the valve seat 22 as in the case of 12). The chart shows the voltage applied to the piezoelectric actuator 34 versus the position of the valve closing structure 18 . Unlike FIG. 3 where the sealing voltage Vs is the maximum firing profile voltage, in FIG. 5 the sealing voltage Vs is the minimum firing profile voltage. Here, the starting voltage 36 is zero volts. The valve closing structure 18 separates from the valve seat 22 at a predetermined location using a voltage relative to the impact voltage. As shown, at impact position 54, valve closing structure 18 moves only a few microns in the voltage range of 0 to 60 volts. Sealing occurs in this voltage range, with lower voltages corresponding to higher sealing forces. In the non-impact position 52, the valve closing structure 18 moves away from the valve seat 22 as the voltage increases in the range of 70 to 110 volts. In the 60 to 70 volt range, it transitions from sealing to motion. Using this arrangement where the sealing voltage Vs is the minimum voltage, the closing voltage Vc is the voltage at which the tip 70 of the valve closing structure 18 last strikes the valve seat 22 . The control component 14 generates a first trend line 72, preferably a linear trend line, for example from a substantially linear portion of the impact position data. The control component 14 also generates a second trend line 74, preferably a linear trend line, for example from a substantially linear portion of the non-impact position data. Specifically, FIG. 5 has a first linear trend line at y = 0.1x + 997 microns, and a second linear trend line at y = 3.24 x + 799.4 microns. Although trend lines using linear equations are shown and explained, trend lines may alternatively use higher order or piecewise equations.

With continuing reference to FIG. 5 , control component 14 determines, for example, the intersection of first trend line 72 and second trend line 74 . This intersection point is regarded as a reference point RP having a closing voltage Vc. The reference point RP (and/or the closure voltage Vc implemented here) is used to determine the calibrated firing profile 60 . In particular, reference point RP in Figure 5 occurs at 1003.3 microns and 62.9 volts. As a result, the original ejection profile 58 has a maximum voltage (or minimum voltage depending on the particular divider 12 configuration) corresponding to the closing voltage Vc plus the sealing offset voltage Vso (i.e., the sealing voltage Vs). ) is shifted to the corrected injection profile 60 to include. As mentioned above, for the injection system considered with respect to FIG. 5 , since the sealing voltage Vs is smaller than the closing voltage Vc, the sealing offset voltage Vso is negative.

6 depicts another illustrative embodiment of an implementation of at least a portion of method 400 . In particular, FIG. 6 shows a chart plotting the measured position (ie, position data 78) of valve closing structure 18 versus the voltage applied to piezoelectric actuator 34 (ie, voltage data 76). The chart shown in FIG. 6 is the alternative distributor 12 configuration described above where the voltage applied to the piezoelectric actuator 34 (and thus its expansion) moves the actuating pin 24 downward and into contact with the poppet 26. It should be noted that it is considered

In Figure 6, the voltage increases from 20 volts to 110 volts in 100 incremental steps. This increases the voltage by 0.9 volts at each step (100 steps/(110 volts - 20 volts)). Tip 70 of valve closing structure 18 impinges on valve seat 22 at closing voltage Vc. In particular, as the positional data 78 is analyzed, one or more successive non-varying positions represent the reference point RP (and hence the closing voltage Vc) generated at the first of these positions. The number of consecutive non-changing positions can be selected by the user using a graphical user interface (GUI). This first position is a reference point RP with a closing voltage Vc of approximately 55 volts. Four non-changing positions have been found to be adequate, but more or less non-changing positions may be needed. As noted above, the original firing profile 58 is shifted to a corrected firing profile 60 based at least in part on the determined lock-down voltage Vc.

This method 400 of calibrating the ejection profile provides many advantages. First of all, this method provides a more consistent injection result across injection systems 10 and is widely applicable to a variety of injection systems 10 . For a given set of hardware components, the impact location varies by about 40 micrometers, which corresponds to about 20 volts for the injection system 10 of FIG. This is particularly problematic when attempting to define a spray profile for multiple injection systems 10 using a single spray profile. Instead, this method allows the peak voltage and crash voltage to be adjusted for each individual injection system 10 and for each specific configuration of hardware components within the injection system 10 . Similarly, by calibrating individual components together, the component's tolerance requirements can be reduced, which in turn reduces manufacturing costs associated with hardware components.

This method may reduce wear and associated replacement costs of hardware components such as valve seat 22 , valve closing structure 18 , and piezoelectric actuation mechanism 16 . Additionally, by using this method periodically as part of a preventative maintenance routine, method 400 can be used to reduce the risk of damage to the injection system 10 as wear of hardware components changes the relative positioning and shutdown voltages Vc. Provides more consistent dispensing over life. These include the distance the valve closing structure 18 travels from the valve seat 22 during opening, the amount of time the valve closing structure 18 is separated from the valve seat, and the valve closing structure 18 being strongly associated with the valve seat when closed. The speed of contact is important because it affects the volume and consistency of the spraying process. By calibrating the injection profile for the closing voltage Vc, this improves the consistency of performance within the lifetime of the injection system 10. Additionally, since the valve seat 22 typically wears out more quickly due to repeated contact with the valve closing structure 18, the valve seat 22 may be used, for example, by the piezoelectric actuation mechanism 16 or the valve closing structure 18. It needs to be replaced before other components such as

This method 400 allows the original spray profile 58 to be calibrated to account for the specific material properties of the fluid substance 38 being dispensed. For example, it is desirable to reduce the impact velocity and increase the sealing force with a low viscosity fluid material. This is because the velocity required to fully expel fluid material 38 from outlet 40 is reduced. Also, for low viscosity fluid materials, it is desirable to increase the sealing force to prevent unintentional leakage of fluid material 38 through outlet 40. As used herein, a low viscosity fluid material generally has a viscosity of about 100 centipoise. Conversely, for high viscosity fluid materials, it is desirable to increase the impact velocity while reducing the sealing force. As used herein, a high viscosity fluid material generally has a viscosity greater than about 1000 centipoise.

7-9 also show another exemplary embodiment in which the injection system 10 incorporates a reference cartridge 80 . In particular, FIGS. 7 and 8 show a reference cartridge 80 comprising a cylinder 82 , a mechanical stopper 84 , and a holder 86 . The reference cartridge 80 is preferably positioned in the same location as the brand new fluid cartridge 56. As shown, the mechanical stopper 84 is preferably a block of known dimensions manufactured with a high degree of precision.

Incorporating the reference cartridge 80 into the injection system 10 provides a “master calibration” that determines the relative wear between the fluid cartridge 56 and the remainder of the injection dispenser 12 . Reference cartridge 80 may also be used to determine wear of other components of system 10, such as valve closing structure 18 and/or piezoelectric actuation mechanism 16. 9 shows valve closing structure 18 as actuation pin 24, valve closing structure 18 may be any of elements known to those skilled in the art such as, for example, poppets, needles, plungers and/or balls. may include an appropriate combination of

10 shows an exemplary method for calibrating an injection system 10 using a reference cartridge 80 having a mechanical stopper 84 positioned at a predetermined distance from the valve closing structure 18 in a non-impact calibration position ( 1000) is shown. In step 1002, fluid cartridge 56, which includes a portion of valve closing structure 18, shown in FIG. 1 as poppet 26 in particular, is removed from injection system 10, while reference cartridge 80 It is inserted into the injection system 10 as shown in FIG. 9 . Removing these components and replacing them with reference cartridge 80 reduces the variability imposed by fluid cartridge 56 (e.g., valve seat 22), and more precise calibration due to fewer components. allow In step 1004, a voltage is applied to the piezoelectric actuator 34 to move the valve closing structure 18 between the non-impact corrected position and the impact corrected position. As used herein, a crash-corrected position is a position where at least a portion of the valve closing structure 18 impacts the mechanical stopper 84, whereas a non-impact-corrected position does not affect any part of the valve closing structure 18. It is a position that does not collide with the mechanical stopper 84. It does not matter whether the valve closing structure 18 is moved from the non-impact corrected position to the impact corrected position or from the impact corrected position to the non-impact corrected position. In particular, FIG. 9 shows the actuating pin of the valve closing structure 18 in contact with the mechanical stopper 84 instead of the poppet 26 of the valve closing structure 18 in contact with the valve seat 22 as shown in FIG. (24) is shown.

In step 1006, the sensing device 48 directly or indirectly senses the position of the valve closing structure 18 while the valve closing structure 18 is actuated by the applied voltage of step 1004. For example, sensing device 48 may sense the position of valve closing structure 18 , such as actuation pin 24 . In step 1008, voltage correction data is generated based on the known voltage applied to the piezoelectric actuator 34 in step 1004, and position correction data is generated based on the sensed position of the valve closing structure 18. do. This generation of voltage calibration data and position calibration data may occur concurrently with or after measuring the movement of the valve closing structure 18 .

At step 1010, control component 14 establishes a master reference point (MRP) using, for example, voltage calibration data and position calibration data. The method of determining the master reference point (MRP) may be performed in a manner similar to the method of determining the reference point (RP) described above with respect to method 400 . Both seek to determine the closing voltage (Vc), but in this exemplary method, the closing voltage (Vc) is the first or last (depending on the arrangement of components) at least a portion of the valve closing structure 18 to the mechanical stopper 84. It is determined when it collides with).

At step 1012, control component 14 determines one or more wear characteristics of injection system 10 by comparing the master reference point to historical data as described below (MRP). ) is used. Method 1000 can also include alerting a user when a wear characteristic of a component is outside acceptable tolerances or when a component requires preventative maintenance. For example, a user may be alerted via a graphical user interface associated with control component 14 . The method includes tracking the number of cycles in which the valve closing structure 18 impacts the mechanical stopper 84, determining the useful life of the component, and using the voltage and position calibration data and the number of cycles to prevent Determining an optimal maintenance schedule and routine may also be included.

Using the reference cartridge 80 to calibrate the ejection cartridge 10 helps determine whether hardware components are at or near the end of their useful life. This master calibration determines the overall wear of the injection distributor 12, but does not determine the relative wear between the piezoelectric actuator mechanism 16 and the valve closing structure 18. However, storing the closing voltage Vc associated with the reference cartridge 80 from when the reference cartridge 80 was new and at various other times allows tracking of wear and improved preventative maintenance. For example, the master reference point (MRP) may be determined and stored multiple times over a period of time. A current master reference point (MRP) may be currently determined and compared to one or more stored master reference points (MRPs). If a difference between the current master reference point (MRP) and one or more stored reference points (MRP) is observed, this may indicate wear of one or more components of the dispenser 12 .

Additionally, comparing the closing voltage Vc corresponding to the replaced components of the fluid cartridge 56 and/or valve closing structure 18 to the closing voltage Vc corresponding to the reference cartridge 80 may result in a valve seat Track wear of replaced components of fluid cartridge 56 and/or valve closing structure 18, including wear of (22). For example, if the reference cartridge 80 is configured such that the relative positioning of the mechanical stopper 84 (relative to the drive pin) matches the relative position of the poppet 26 in a non-wear state, then the reference cartridge 80 The difference between the corresponding closing voltage (Vc) and the previously recorded closing voltage (Vc) corresponding to the current poppet (26) indicates wear in the replaced poppet (26) and/or the replaced valve seat (22). can reveal Similarly, this difference may cause wear in the piezoelectric actuation mechanism 16 (or components thereof), for example, since more voltage may be required to inflate the non-wearing piezoelectric actuator 34 over the same distance. can reveal

In another exemplary embodiment, a user's method of operating an injection system 10 that includes a mechanical stopper 84 positioned a predetermined distance away from a valve closing structure 18 in a non-impact corrected position is also disclosed. . In this embodiment, a user enters various parameters into control component 14 using a graphical user interface (not shown) electronically connected to control component 14 . By way of example, and not limitation, the user may enter fluid type, ejection frequency, and/or droplet size. Based at least in part on the parameter(s) provided by the user, the control component 14 then operates the piezoelectric actuation mechanism 16 to move the valve closing structure 18 between the non-impact corrected position and the impact corrected position. Applying a voltage to the piezoelectric actuator 34 determines the calibrated firing profile 60 . In this embodiment, a crash correction position occurs when the valve closing structure 18 collides or contacts the mechanical stopper 84, depending on the particular configuration of the injection system 10. The method includes applying a correction profile to an injection system (10) using a control component (14). The method moves the valve closing structure 18 between a non-collision correction position in which the valve closing structure 18 does not collide with the valve seat 22 and a collision position in which the valve closing structure 18 collides with the valve seat 22. and determining the spray profile by applying a voltage to the piezoelectric actuator 34 to cause it to move. The method includes applying the calibrated spray profile 60 to the spray system 10 . A graphical user interface or audible alert can be made by the control component 14 to alert the user when wear exceeds recommended levels or when preventive maintenance is required.

11 shows an exemplary method 1100 for calibrating the injection system 10 and/or determining wear of the injection system 10 using the stroke length of the valve closing structure 18 specified by the user. The method 1100 may be used to account for changes in, for example, the piezoelectric actuation mechanism 16 , the valve closing structure 18 , and/or other components of the injection system 10 . For example, due to repeated use or simple slight changes in manufacturing, the "benefit" of the system may change. That is, the displacement caused by the piezoelectric actuation mechanism 16 per unit of applied voltage may vary from particular system to particular system.

At step 1102, a desired stroke length of valve closing structure 18 is received from a user. The required stroke length may specify, for example, the required stroke length of the poppet 26 from its uppermost non-impact position with the valve seat 22 to its impact position. In some aspects, the user may also input seal offset voltage (Vso) or other parameters related to the operation of injection system 10 . Step 1102 of method 1100 as well as other steps may be performed via control component 14 .

At step 1104, a voltage is applied to the piezoelectric actuator 34 to move the valve closing structure 18 (eg, poppet 26) between the non-impact and impact positions (or vice versa). At step 1106, the position(s) of the valve closing structure 18 are sensed by the sensing device 48 as the valve closing structure 18 moves between the non-impact and impact positions (or vice versa). . In step 1108, based on the known voltage applied to the piezoelectric actuator 34 in step 1104 and the sensed position(s) in step 1106, voltage and position data are generated.

At step 1110, a reference point RP is determined based on analysis of the voltage and position data. Reference point RP may be determined in a manner similar to that described above with respect to method 400 shown in FIG. 4 and the illustrative example of FIGS. 5 and 6 . Based on the reference point RP, the closing voltage Vc may be additionally determined. For example, the voltage component of the reference point RP may represent the closed voltage Vc.

At step 1112, the voltage and position data are analyzed to determine the highest voltage (Vt). The highest voltage Vt is the voltage that, when applied to the piezoelectric actuator 34, provides the required stroke length received from the user in step 1102. In particular, the highest voltage (Vt) is the voltage that provides the maximum upward movement of the valve closing structure (eg, poppet 26) relative to the valve seat 22, hence the term "highest" voltage. As such, the highest voltage Vt may be the maximum voltage applied to the spray profile for the distributor 12, where the voltage applied to the piezoelectric actuator 34 is the voltage applied to the distributor 12 shown in FIGS. 1 and 1A. ) to move the valve closing structure 18 away from the valve seat 22. Conversely, the highest voltage Vt may be the minimum voltage applied to the injection profile for the distributor 12, where the voltage applied to the piezoelectric actuator 34 moves the valve closing structure 18 towards the valve seat 22. ) to move.

In step 1114, the closing voltage Vc and/or the reference point RP are used to shift the original firing profile 58 into a first corrected firing profile 60a. The determination of the first corrected firing profile 60a is in a manner similar to the determination of the corrected firing profile 60 described in step 412 of method 400 and in the illustrative examples provided in FIGS. 3 , 5 and 6 . can be performed with For example, the first corrected firing profile 60a is equal to or equal to the closing voltage Vc if the sealing offset voltage Vso is provided or otherwise accessible. It may be determined to have a start voltage and/or an end voltage equal to the sealing voltage Vs.

In step 1116, the highest voltage Vt is used to determine the second calibrated firing profile 60b. In particular, the first corrected spray profile 60a is stretched or compressed relative to the closing voltage Vc (or sealing voltage Vs as the case may be) to form the second corrected spray profile 60b, so that the second corrected spray profile 60b is formed. The minimum voltage (at the distributor 12 at which the applied voltage causes a downward movement of the valve closing structure 18 towards the valve seat 22) or the maximum voltage (the applied voltage at the valve seat 22) of the injected profile 60b. At distributor 12 causing an upward movement of valve closing structure 18 away from 22) is equal to the highest voltage Vt. It should be noted that steps 1114 and 1116 can be performed in the reverse order shown in FIG. 11 . For example, the original spray profile 58 can first be stretched or retracted based on the highest voltage Vt, and the resulting profile shifted according to the closing voltage Vc and/or the sealing voltage Vs. can Similarly, steps 1114 and 1116 may be performed concurrently.

Referring to FIGS. 12 and 13 , an illustrative example of method 1100 will now be provided. FIG. 12 is similar in many respects to FIG. 3 and shows the original firing profile 58 as well as a first corrected firing profile 60a and a second corrected firing profile 60b. FIG. 13 is similar in many respects to FIG. 6 and includes a chart of measured position data 78 displayed in voltage data 76 . The chart of FIG. 13 includes data during the non-impact position 52 (ie, the valve closing structure 18 moves towards the valve seat 22) and during the impact position 54. The gradient of the chart line during the non-impact position can be considered a voltage “gain” versus the displacement of this particular divider 12 .

Initially, the user provides an input of 50 micrometers for the required stroke length 1302 of the valve closing structure 18, as well as a sealing voltage offset (Vso) of approximately 5 volts, such as via the control component 14. do. A voltage is applied to the piezoelectric actuator 34, the position(s) of the valve closing structure 18 is sensed by the sensing device 48, and position data 78 and voltage data 76 are responsively generated. Using the methodology described in more detail above, voltage data 76 and position data 78 are analyzed to determine a reference point RP, shown in FIG. 13 , which here corresponds to approximately 55 volts and approximately 1145 micrometers. do.

Based on the closing voltage Vc (55V) of the reference point RP, a first corrected firing profile 60a is determined. The first corrected firing profile 60a is such that the maximum voltage of the first corrected firing profile 60a is equal to the sealing voltage Vc plus the sealing offset voltage Vso to the closing voltage Vc. (58). In this example, the maximum voltage of the first calibrated firing profile 60a is 60 volts (55 volts + 5 volts).

The second corrected firing profile 60b is determined based at least in part on the highest voltage Vt. In particular, the second corrected firing profile 60b is obtained by stretching or compressing the first corrected firing profile 60a such that the minimum voltage of the second corrected firing profile 60b is equal to the highest voltage Vt. It is decided. The highest voltage (Vt) can be determined by analysis of the chart data in FIG. 13 . For example, given that the reference point RP has already been determined, the required stroke length 1302 (ie, the change in the position of the valve closing structure 18) can be subtracted from the position of the reference point RP. Here, this would result in a position of 1095 microns (1145 μm - 50 μm = 1095 μm). The position of 1095 micrometers can be cross-referenced on the data line of the chart to determine that the position of 1095 micrometers corresponds to the highest voltage (Vt) of about 37 volts.

As another technique for determining the peak voltage (Vt), the chart data of FIG. 13 during the non-impact position 52 can be extrapolated to a trend line. A trend line can be described in the form of the equation y = mx + c, where y is the measured position, x is the voltage, m is the slope of the line, and c is a constant constant. The highest voltage (Vt) is determined by setting y in the above equation to be 1095 micrometers (i.e., the difference between the position of the reference point (RP) and the specific required stroke length 1302), and x yielding the highest voltage (Vt). can be determined by solving It will be appreciated that these and other techniques for determining the highest voltage (Vt) may be implemented through software executable by control component 14 .

Using the highest voltage Vt determined to be 37 volts, the first calibrated firing profile 60a is second calibrated such that the minimum voltage of the second calibrated firing profile 60b is 37 volts as can be seen in FIG. 12 . It can be compressed into the spray profile 60b.

14 shows, as shown in FIGS. 7 to 9, using a reference cartridge 80 having a mechanical stopper 84 positioned a predetermined distance away from the valve closing structure 18 in the non-impact corrected position, An exemplary method 1400 for calibrating the injection system 10 and/or determining wear characteristics (including electrical degradation) of the injection system 10 is shown.

At step 1402, the fluid cartridge 56 is removed from the injection system 10 and replaced with a reference cartridge 80. At step 1404, a voltage is applied to the piezoelectric actuator 34 to move the valve closing structure 18 between the non-impact corrected position and the impact corrected position. As used herein, a crash-corrected position is a position where at least a portion of the valve closing structure 18 impacts the mechanical stopper 84, whereas a non-impact-corrected position does not affect any part of the valve closing structure 18. It is a position that does not collide with the mechanical stopper 84. For example, drive pin 24 may contact mechanical stopper 84 at the impact position instead of poppet 26 contacting valve seat 22 in the configuration shown in FIG. 1 .

At step 1406, the sensing device 48 directly or indirectly senses the position of the valve closing structure 18 while the valve closing structure 18 is actuated by the applied voltage of step 1404. In step 1408, voltage correction data is generated based on the known voltage applied to the piezoelectric actuator 34 in step 1404, and position correction data is generated based on the sensed position of the valve closing structure 18. . The generation of such voltage calibration data and position calibration data may occur concurrently with or after measurement of the movement of the valve closing structure 18 .

In step 1410, a reference “gain” is determined, which reflects the ratio of the displacement of the valve closing structure 18 to the voltage applied to the piezoelectric actuator 34. For example, charts corresponding to non-conflict calibration positions, since the calibration position and voltage data can be plotted relative to each other in the same way as position data 78 and voltage data 76 shown in FIG. 6 or 13 . The data line at can be analyzed to determine a trend line. The gradient of the trend line may correspond to the reference gain. The reference gain may be stored for later use, such as in a comparison of one or more stored reference gains to a current reference gain.

In step 1412, the reference gain is determined to determine the wear characteristics (including electrical degradation) of the dispenser 12 or components thereof comprising the valve seat 22, the valve closing structure 18, or the piezoelectric actuation mechanism 16. is used to determine For example, a reference gain can be compared against a predetermined range of gains that reflect a “normal” gain. If the reference gain falls outside the predetermined range of gain, this may indicate that the dispenser 12 or its components have suffered detrimental wear and may require maintenance or replacement. As another example, the current reference gain can be compared to a past reference gain for the same divider 12 . If the difference between the current reference gain and the past reference gain is greater than a predetermined threshold, this may also indicate wear. Upon determining the wear characteristics, the user may be notified, such as through an audible signal or a graphical user interface associated with the control component 14 .

As referred to herein, the control component 14 may be any type of processing (or computing) device having one or more processors. For example, control component 14 may be an individual processor, workstation, mobile device, computer, cluster of computers, set top box, game console, or other device having at least one processor. In an embodiment, more than one control component 14 may be implemented in the same processing device. Such a processing device may include software, firmware, hardware, or a combination thereof. Software may include one or more application programs and operating systems. The hardware may include, but is not limited to, a processor, memory and/or graphical user display. Control component 14 may be disposed as part of dispenser 12 and/or as a separate component from dispenser 12 .

Although the present invention has been illustrated by the description of specific embodiments thereof and embodiments have been described in considerable detail, it is not intended that the scope of the appended claims be limited to such detailed description or in any way limit the scope of the appended claims. The various features described herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods and exemplary embodiments shown and described. Accordingly, it may be made from these details without departing from the scope or spirit of the inventive concept.

Claims (33)

A dispensed fluid material for an injection system comprising a dispense distributor and a control component operably coupled to the dispense dispenser, wherein the dispense dispenser comprises a piezoelectric actuation mechanism having a valve seat, a valve closing structure, and a piezoelectric actuator. As a method of calibrating the injection profile of
Applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-collision position in which the valve closing structure does not collide with the valve seat and an impact position in which at least a portion of the valve closing structure collides with the valve seat. step;
generating voltage data when the valve closing structure moves;
sensing a position of the valve closing structure using a sensing device when the valve closing structure moves;
generating positional data when the valve closing structure moves;
setting a reference point using the voltage and position data; and
and using the reference point to adjust the voltage applied to the piezoelectric actuator. The method of claim 1 , further comprising: generating velocity data as the valve closing structure moves; and
and establishing a reference point using the voltage, position, and speed data. The method of claim 2, wherein the step of using the reference point,
and using said fiducial to reduce impact velocity and increase sealing force for low viscosity fluid materials. The method of claim 2, wherein the step of using the reference point,
and using said fiducial to increase impingement velocity and reduce sealing force for high viscosity fluid materials. The method of claim 1, wherein the step of using the reference point,
and using the reference point to determine a wear characteristic of at least one of the piezoelectric actuation mechanism, the valve closing structure, and the valve seat. 2. The method of claim 1, wherein the sensing device further comprises a linear encoder. The method of claim 1, wherein the step of sensing the position of the valve closing structure,
The method further comprising sensing the position of the valve closing structure using a sensing device directly attached to the valve closing structure. 2. The method of claim 1, wherein establishing a reference point using the voltage and position data further comprises displaying the voltage and position data. The method of claim 1, wherein the location data further includes non-collision and collision location data, and the setting of the reference point comprises:
generating a first trend line from at least a portion of the non-collision position data;
generating a second trend line from at least a portion of the impact location data; and
determining an intersection of the first and second trend lines to establish the reference point. 10. The method of claim 9, wherein generating the first and second trend lines and determining the intersection comprises:
generating a first linear trend line from a linear portion of the non-collision position data;
generating a second linear trend line from the linear portion of the impact position data; and
determining an intersection of the first and second linear trend lines to establish the reference point. a piezoelectric actuation mechanism comprising a spray distributor and a control component operatively coupled to the spray distributor, wherein the spray distributor has a piezoelectric actuator; a valve closing structure; and a predetermined distance from the valve closing structure in a non-impact corrected position. A method of calibrating the ejection profile of an ejected fluid material for an ejection system comprising mechanical stoppers spaced apart by
apply a voltage to the piezoelectric actuator to move the valve closing structure between the non-collision correction position where the valve closing structure does not collide with the mechanical stopper and the collision correction position in which at least a portion of the valve closing structure collides with the mechanical stopper; applying;
generating voltage correction data when the valve closing structure moves;
sensing a position of the valve closing structure using a sensing device when the valve closing structure moves;
generating position correction data when the valve closing structure moves;
setting a master reference point using the voltage and position calibration data; and
and using the master fiducial to determine wear of at least one of the piezoelectric actuation mechanism and the valve closing structure. 12. The method of claim 11, wherein the step of using the master reference point,
storing the master reference point over a period of time;
comparing a current master reference point with the stored master reference point; and
and using the comparison to determine wear or predict preventative maintenance of at least one of the piezoelectric actuation mechanism and the valve closing structure. 12. The method of claim 11, wherein the step of using the master reference point,
storing the position and voltage calibration data over a period of time;
comparing the current position and voltage calibration data with the stored position and voltage calibration data; and
and using the comparison to determine wear or predict preventative maintenance of at least one of the piezoelectric actuation mechanism and the valve closing structure. 12. The method of claim 11, wherein the piezoelectric actuation mechanism comprises:
a piezoelectric stack including a plurality of piezoelectric elements; and
and an amplifier positioned between the piezoelectric stack and the valve closing structure. 15. The method of claim 14, further comprising alerting a user when wear of at least one of the piezoelectric actuation mechanism and the valve closing structure is out of tolerance. 15. The method of claim 14 further comprising: tracking the number of cycles in which the valve closing structure impacts the valve seat; and
determining a useful life of at least one of the piezoelectric actuation mechanism, the valve closing structure, and the valve seat using the voltage and position calibration data and the number of cycles. 17. The method of claim 16, further comprising alerting a user to a useful life of at least one of the piezoelectric actuation mechanism, the valve closing structure, and the valve seat. 15. The method of claim 14 further comprising: tracking the number of cycles in which the valve closing structure impacts the valve seat;
determining a need for preventative maintenance of at least one of the piezoelectric actuation mechanism, the valve closing structure, and the valve seat using the voltage and position calibration data and the number of cycles. . 19. The method of claim 18, further comprising alerting a user to a need for preventive maintenance on at least one of the piezoelectric actuation mechanism, the valve closing structure, and the valve seat. an inject distributor and a control component operably coupled to the inject distributor, wherein the inject distributor is configured to obtain a valve seat, a valve closure structure, a piezoelectric actuation mechanism having a piezoelectric actuator, and a valve closure structure in a non-impact corrected position. A method of calibrating the ejection profile of an ejected fluid material for an ejection system comprising mechanical stoppers positioned a predetermined distance apart, comprising:
applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-impact position in which the valve closing structure does not collide with the valve seat and an impact position in which at least a portion of the valve closing structure collides with the valve seat; ;
generating voltage data when the valve closing structure moves;
sensing a position of the valve closing structure using a sensing device when the valve closing structure moves;
generating positional data when the valve closing structure moves;
setting a reference point using the voltage and position data;
apply a voltage to the piezoelectric actuator to move the valve closing structure between the non-collision correction position where the valve closing structure does not collide with the mechanical stopper and the collision correction position in which at least a portion of the valve closing structure collides with the mechanical stopper; applying;
generating voltage correction data when the valve closing structure moves;
sensing a position of the valve closing structure using the sensing device when the valve closing structure moves;
generating position correction data when the valve closing structure moves;
setting a master reference point using the voltage calibration data and the position calibration data; and
comparing the reference point to the master reference point to determine wear of the valve seat. a piezoelectric actuation mechanism having a piezoelectric actuator, a valve seat, a valve closure structure, and a control component operatively coupled to the injection distributor; A method for a user to actuate an injection system comprising mechanical stoppers positioned a predetermined distance apart, comprising:
receiving input from a user via the control component of an operating parameter representative of at least one of a fluid type, an ejection frequency, and a droplet size;
the valve closing structure, based at least in part on the operating parameters, between a non-collision corrected position in which the valve closing structure does not collide with the mechanical stopper and a collision corrected position in which at least a portion of the valve closing structure collides with the mechanical stopper; determining a master calibration profile by applying a voltage to the piezoelectric actuator to move the;
applying the master calibration profile to the injection system using the control component;
applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-collision correction position in which the valve closing structure does not collide with the valve seat and a collision correction position in which at least a portion of the valve closing structure collides with the valve seat; determining a calibrated spray profile by and
and applying the calibrated injection profile to the injection system. performing maintenance on an injection system comprising a dispense distributor and a control component operably coupled to the dispense dispenser, wherein the dispense dispenser includes a piezoelectric actuation mechanism having a valve closing structure, a valve seat, and a piezoelectric actuator. As a method,
applying a voltage to the piezoelectric actuator to move the valve closing structure between a first position and a second position;
generating voltage data when the valve closing structure moves;
sensing a position of the valve closing structure using a sensing device when the valve closing structure moves;
generating positional data when the valve closing structure moves; and
and using the voltage data and the position data for preventative maintenance of one or more components of the injection system. 23. The method of claim 22, wherein the one or more components are at least one of the piezoelectric actuation mechanism, the piezoelectric actuator, the valve seat, and the valve closing structure. 23. The method of claim 22, further comprising using the voltage data and the location data to generate an alert indicating a need for the preventive maintenance. 23. The method of claim 22, wherein using the voltage data and the position data comprises:
The method further comprising using the voltage data and the position data to determine wear characteristics of the one or more components. 26. The method of claim 25, further comprising generating an alert indicative of said wear characteristics. of a dispensing fluid material for an injecting system comprising a dispensing distributor and a control component operably coupled to the dispensing distributor, wherein the injecting distributor comprises a piezoelectric actuation mechanism having a valve seat, a valve closing structure, and a piezoelectric actuator. As a method of calibrating the injection profile,
receiving an input of a required stroke length of the valve closing structure from a user;
applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-impact position in which the valve closing structure does not collide with the valve seat and an impact position in which at least a portion of the valve closing structure collides with the valve seat; ;
generating voltage data when the valve closing structure moves;
sensing a position of the valve closing structure using a sensing device when the valve closing structure moves;
generating positional data when the valve closing structure moves;
based at least in part on the voltage data and the position data, determining a reference point;
determining, based at least in part on the voltage data and the position data, a highest voltage corresponding to a position of the valve closing structure that results in a required stroke length of the valve closing structure; and
and using the reference point and the highest voltage to adjust the voltage applied to the piezoelectric actuator. 28. The method of claim 27, wherein using the reference point and the highest voltage to adjust the voltage applied to the piezoelectric actuator comprises:
adjusting the voltage to a voltage implemented by the reference point, corresponding to a position of the valve closing structure in contact with the valve seat; and
adjusting the voltage to the highest voltage, corresponding to a position of the valve closing structure at a maximum distance from the valve seat. 28. The method of claim 27, wherein the location data further includes non-collision and collision location data, and the step of determining the reference point comprises:
generating a first trend line from at least a portion of the non-collision position data;
generating a second trend line from at least a portion of the impact location data; and
determining an intersection of the first and second trend lines to determine the reference point. 30. The method of claim 29, wherein determining the highest voltage comprises:
determining a position of the valve closing structure by determining a difference between a position realized at the singi reference point and a required stroke length of the valve closing structure; and
determining the highest voltage using the location of the valve closing structure and the first trend line. a piezoelectric actuation mechanism comprising a spray distributor and a control component operatively coupled to the spray distributor, wherein the spray distributor has a piezoelectric actuator; a valve closing structure; and a predetermined distance from the valve closing structure in a non-impact corrected position. A method of calibrating the ejection profile of an ejected fluid material for an ejection system comprising mechanical stoppers spaced apart by
Applying a voltage to the piezoelectric actuator to move the valve closing structure between a non-collision correction position in which the valve closing structure does not collide with the mechanical stopper and a collision correction position in which at least a portion of the valve closing structure collides with the mechanical stopper. doing;
generating voltage correction data when the valve closing structure moves;
sensing a position of the valve closing structure using a sensing device when the valve closing structure moves;
generating position correction data when the valve closing structure moves;
determining, based at least in part on the voltage calibration data and the position calibration data, a reference gain representative of a ratio of displacement of the valve closing structure to a voltage applied to the piezoelectric actuator; and
determining a wear characteristic of at least one of the piezoelectric actuation mechanism and the valve closing structure based, at least in part, on the reference gain. 32. The method of claim 31, wherein determining the wear characteristics comprises:
storing the reference gain over a period of time;
comparing the stored reference gain to a current reference gain; and
and using the comparison to determine wear or predict preventative maintenance of at least one of the piezoelectric actuation mechanism and the valve closing structure. 32. The method of claim 31, wherein determining the wear characteristics comprises:
comparing the reference gain to a predetermined range of gains; and
and using the comparison to determine wear or predict preventative maintenance of at least one of the piezoelectric actuation mechanism and the valve closing structure.

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